Quick Question-Fuel Cap
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Thread: Quick Question-Fuel Cap

  1. #1
    Junior Member Olympus's Avatar
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    Quick Question-Fuel Cap

    Is it normal for the fuel tank cap to be so hard to unscrew? I have to use two hands and squeeze like hell with both just to get it to unscrew. I mean itís on there right!
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  2. #2
    Senior Member Miaugi's Avatar
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    Ok if I was being silly....you do know there is a lock and you need a key right?

    Seriously though I have no trouble with mine and I do not recall ever seeing a similar complaint so it may be just your bike. Is there any signs of damage or rust? Perhaps the rubber seal is swollen and is too tight? Completely the wrong cap?

    Good luck getting this sorted out!
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  3. #3
    Senior Member Peterb's Avatar
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    I use a little silicone grease or even vaseline on the rubber once in a while
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  5. #4
    Junior Member Olympus's Avatar
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    Yes, itís unlocked. No rust. I guess it is possible that the seal could be swollen. I mean this thing is a bear to get off.
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    Senior Member TW-Brian's Avatar
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    The gas caps on the 2001+ model years are smaller in diameter than the earlier years, and my 2005 usually took two hands for me to get it open.

  7. #6
    Junior Member Olympus's Avatar
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    My bike is a 2000 model.
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  8. #7
    Super Moderator Purple's Avatar
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    Mines a ’98 – same larger diameter fuel cap, and yes, it can be an absolute pig to remove

    It’s the rubber washer sticking to the metal of the tank, so a bit of Vaseline between the two would help …..
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  9. #8
    Senior Member RockyTFS's Avatar
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    My brand new 2018 requires some force, but not so much that I need both hands. It's unlikely that the rubber seal is swollen, but fairly likely that it has gotten brittle after 19 years. This will make it harder to turn because there is no give in the material anymore. If the seal doesn't give to the pressure of a fingernail impressed into it replace it before doing the next thing.

    Use some 400 and 600 grit sandpaper to aggressively polish the underside of the lip, then put some silicone grease on the rubber seal. Try pressing down on the cap while turning. If this has no effect, get a bright light and an inspection mirror and look at both the underside of the lip and the area on the tabs that contacts the lip. Remove material a tiny bit at a time on both until the cap turns without quite so much force. Put some masking tape on the hole so you don't get any metal powder in the tank.
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  10. #9
    Junior Member Olympus's Avatar
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    Quick Question-Fuel Cap

    Iíll try a little Vaseline around the rubber gasket. I bet thatís what the problem is.

    A side note, I did my first oil and filter change on the bike today too. I could not get the drain plug off with a 3/8 ratchet. So I took the foot peg off and tried using a cordless impact and that wouldnít budge it either! I ended up having to use a long breaker bar and a 6pt socket and that did the trick. I put it back on to 29 ft/lbs instead of the 31 that the manual says.
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  11. #10
    GOF
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    My '87 was a bear to get turning after sitting so long. But a touch of oil on the seal fixed that right up.
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